Method for consolidating manufacturing of computing devices

ABSTRACT

A system and method of manufacturing of computing devices. The system and method advantageously provide a work cell and process for physically consolidating the transformation process of a computer system (motherboard prep, chassis prep, assembly, EMR, burn, test and boxing) during manufacturing of the same in one work area. The new consolidating manufacturing assembly work cell provides a streamlined process, automation, furniture, fixtures and intelligent controls which physically consolidate the steps of the transformation process. The work cell includes a new combination of equipment for: (1) Material Handling, (2) performing the assembly steps, (3) detecting and repairing electrical and mechanical problems, and (4) performing burn and test. Further, the integration of the transformation process into one consolidated work cell for the manufacture of computer systems enables a new and more versatile manufacturing process. Accordingly, these transformation process steps can be carried out by the same operator/team without having to move a computer system being manufactured to various different parts of the factory during its transformation.

CROSS-REFERENCE TO CO-PENDING APPLICATION

This application is a Divisional of U.S. Ser. No. 09/484,712, filed Jan.18, 2000.

This application relates to co-pending U.S. patent application Ser. No.09/053,524, filed on Mar. 31, 1998, entitled “Manufacturing System andMethod for Assembly of Computer Systems in a Build-to-OrderEnvironment,” naming Lois Goss as inventor. The co-pending applicationis incorporated herein by reference in its entirety, and is assigned tothe assignee of the present invention.

BACKGROUND

The disclosures herein relate generally to computer systems, and moreparticularly, to a process and apparatus for physically consolidatingand streamlining the manufacturing of computer systems in abuild-to-order environment.

Traditionally, manufacturing systems have been designed and constructedbased upon a build-to-stock model where large quantities of identicalproducts are assembled to meet forecasted demand and warehoused untilthat demand occurs. Such manufacturing systems provide economies ofscale based upon the large quantities of identical units and can beoptimized by increasing the speed with which each manufacturing step iscompleted. Because build-to-stock manufacturing systems rely on knownproduct configurations, each step in the manufacturing process is knownin advance, and so the manufacturing system utilizes progressive buildtechniques to optimize each stage in the serial assembly process. Forproducts (e.g. a computer system) that include sensitive components,progressive build manufacturing systems can be carefully planned inadvance to protect those sensitive components. Once the manufacturingsystem becomes operational, it will build the same product repeatedly,using the optimized steps.

However, when the process is adapted to build a different product, or adifferent version of the same product, the manufacturing system must bemodified and re-optimized to ensure that the system still protectssensitive components. Moreover, since the progressive build process isserial, each stage depends on timely completion of the previous stage,and thus the entire process is susceptible to problems, inefficiencies,and failures in any of the stages of the system. Additionally,progressive-build manufacturing systems operating in a build-to-stockenvironment are relatively inflexible, limiting the ability of themanufacturing system to fill small orders economically and to controlinventory.

One method used to increase performance in progressive-buildmanufacturing processes is to include a process step in which identicalkits are prepared that hold the components needed to assemble aparticular product or to complete a particular manufacturing step. Inthis way some of the time normally required to select parts for aparticular product or manufacturing step can be reduced, and somemanufacturing steps can more easily be performed in one location or byone operator or piece of manufacturing equipment (e.g. an industrialrobot). For example, U.S. Pat. No. 4,815,190 discloses the use ofautomated and manual kitting stages for producing identical kits forautomobile sub-assemblies. One advantage to using identical kits is thatit is relatively easy to know if all of the parts needed to assemble aparticular product are present in the kit; a missing part stands outbecause each kit should always have the same set of components.

As an alternative to progressive-build manufacturing systems which areoften faced with the problem of large dwell times, i.e. time periodswhere a product being assembled must wait before moving to a subsequentassembly stage, some manufacturing systems have been shifted tocontinuous flow manufacturing (CFM) methods. In general. CFM methodsemploy a demand-driven pull system for inventory control and movement ofcomponents into the assembly process. This can include the use of kanbantechniques for inventory control and movement. CFM also supportsmixed-model manufacturing continuous flow production lines. CFM systemsoffer continuous flow of value added activities, eliminating wastedmotion and dwell times. Other terms often used for CFM includeJust-In-Time (JIT) manufacturing, Flexible and Agile Manufacturing,Synchronous Manufacturing and Demand Based Conversion.

Personal computers, servers, workstations, portables, embedded systemsand other computer systems are typically assembled in manufacturingsystems designed for build-to-stock environments. A typical personalcomputer system includes a processor, associated memory and controllogic and a number of peripheral devices that provide input and output(I/O) for the system. Such peripheral devices include, for example,compact disk read-only memory (CD-ROM) drives, hard disk drives, floppydisk drives, and other mass storage devices such as tape drives, compactdisk recordable (CD-R) drives, digital video/versatile disk (DVD)drives, or the like.

Manufacturing computer systems becomes inefficient when the number ofidentical units is decreased and process steps are changed as orderschange, both of which are characteristics of a build-to-orderenvironment where computer systems (or products generally) aremanufactured or assembled only after an order for that particularcomputer system has been placed. As a result, the conventionalmanufacturing systems do not adapt well to the build-to-orderenvironment and can limit the ability to fill small orders, requireextra inventory, generate more work-in-process, and be globallyconstrained by the slowest process step. This process also requires linechangeovers and new tooling when change is required. One attempt toadapt and to improve the efficiency of conventional manufacturingsystems has been to reduce the number of components prepared in advanceof orders. By limiting such in-process inventory, the line can changeconfigurations more easily as orders change. However, this scheme isstill limited in its efficiency for smaller orders in the build-to-orderenvironment.

Because computer systems manufacturers have recognized that abuild-to-order environment is advantageous and often can better react tothe speed with which product designs and customer expectations change,there is a need to provide manufacturing systems and methods that moreefficiently integrate with the build-to-order model while ensuring thathigh quality, defect free products are produced.

Current manufacturing of build-to-order computers is limited by theparticular manufacturing line used. For instance, to double theproductivity of a current factory manufacturing line process for a givenfloor space (in terms of units/hour/square foot (Units/Hr./Sq.Ft.)),additional manufacturing plants will be necessary to meet an increaseddemand. The cost of building new manufacturing plants can besubstantial, for example, at an average cost of approximately $100M ormore per plant. Product quality and manufacturing flexibility suffer,wherein generally only one product line can be built on any givenassembly line at a time. Merely doubling the existing manufacturing lineprocess further suffers from an inability to adjust to changes inproduct demand and an inability to improve floor space utilization. Inaddition, profitability and customer experience suffer degradation witha mere doubling of an existing manufacturing line process.

Referring briefly to FIG. 1. a flow diagram view of a computerbuild-to-order manufacturing process is illustrated. In general, themanufacturing process 10 includes receipt of a customer order 12,kitting of parts 14, motherboard preparation 16, assembly and quick test18, burn (i.e., software download and extended test) 20. FederalCommunication Commission testing (FCC test and label application) 22,high potential (HI POT) testing 24, wipe down (inspection and cleaningof computer chassis) 26, document kitting 28, boxing 30, transport tothe distribution center 32, shipping 34, and finally, customer receipt36.

FIG. 2 illustrates a plan view of various portions of the distributedmanufacturing line in the manufacture of build-to-order computersystems. The distributed manufacturing line is generally indicated bythe reference numeral 10 a. Separate stations or areas are provided foreach of the portions of the distributed manufacturing line, for example,as follows. Motherboard preparation is generally indicated by referencenumeral 16 a. Assembly/quick test is generally indicated by referencenumeral 18 a. Electrical mechanical repair (EMR) is generally indicatedby reference numeral 19. Burn or extended test is generally indicated byreference numeral 20 a. HI POT is generally indicated by referencenumeral 24 a. FCC is generally indicated by reference numeral 22 a.Wipedown is generally indicated by reference numeral 26 a. Lastly,boxing is generally indicated by reference numeral 30 a.

FIG. 3 is a plan view layout of the various portions of the distributedmanufacturing line of FIG. 2. The layout is generally indicated byreference numeral 50. The physical layout of equipment for performingthe various portions of the distributed manufacturing process areillustrated, from left to right. The layout includes kitting 14 a,mother board preparation 16 a, assembly 18 a, EMR 19, burn 20 a, acombination of FCC/HI POT/wipedown (22 a, 24 a, 26 a), boxing anddocumentation 30 a, and direct ship 36 (or distribution center 32 andship 34). The distributed manufacturing line of FIG. 3 is characterizedin that it requires on the order of 22.120 sq. ft. for a potentialproduction yield or rate on the order of 240 units/hour, with apotential plant capacity of on the order of approximately 1200units/hour.

Furthermore, in the manufacturing of build-to-order computing devices,direct ship is an important strategic initiative. Direct ship is amethod for reducing cost per box and speeds product delivery. Directship involves adding special material handling equipment and loadingdock doors at the end of a manufacturing process line. A drawback todirect ship, however, is that direct ship consumes valuablemanufacturing floor space. In order to implement direct ship intoexisting build-to-order manufacturing line buildings, and maintainand/or increase production, a new, higher performing manufacturing linedesign is needed.

In addition to direct ship, competitive pressures are causing theaverage computer price to drop dramatically. In order to maintainmargins, it is critical that new ways to lower manufacturing costs bedeveloped. Accordingly, an improved method of manufacturing of computingdevices is needed.

SUMMARY

One embodiment accordingly provides a consolidated manufacturing cellmethod for the manufacture of custom configured computer systems byproviding a work surface including at least one section suitable for useduring an assembly of a computer system from a kit of parts, providingan elevator including a cargo surface suitable for receiving anassembled computer system and being disposed with respect to the worksurface for vertical movement between at least a first vertical leveland a second vertical level, providing at least one burn slot verticallydisposed with respect to the work surface, the at least one burn slotfurther for receiving an assembled computer system during a prescribedburn processing thereof, and controlling an operation of the elevator todeliver an assembled computer system from the work surface to anavailable burn slot of the at least one burn slot.

A principal advantage of this embodiment is that the new consolidatingmanufacturing assembly work cell provides automation, furniture,fixtures and intelligent controls which physically consolidate the stepsof the transformation process (i.e., chassis prep, mother board prep,assembly, EMR, burn, test and boxing).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a flow diagram view of a computer systembuild-to-order manufacturing process.

FIG. 2 is a plan view of various portions of a distributed manufacturingline in the manufacture of build-to-order computer.

FIG. 3 is a plan view layout of the various portions of the distributedmanufacturing line of FIG. 2.

FIG. 4 illustrates an exemplary computer system that the presentdisclosure can build-to-order.

FIG. 5 illustrates a flow diagram view of a computer systembuild-to-order manufacturing process including use of a consolidatedmanufacturing cell according to the present disclosure.

FIG. 6 is a plan view layout of the manufacturing process according tothe present disclosure.

FIG. 7 is a plan view of a portion of the layout of FIG. 6. enlarged toshow greater detail.

FIG. 8 is a plan view of a consolidated manufacturing cell according toan embodiment of the present disclosure.

FIG. 9 is a Schematic view of the consolidated manufacturing cell infurther detail.

DETAILED DESCRIPTION

The present disclosure can be described with the examples given below.It is understood, however, that the examples below are not necessarilylimitations to the present disclosure, but are used to describe typicalembodiments of operation.

First, in order to provide a foundation to better describe the preferredembodiment of the invention, a typical computer system will bedescribed. Referring briefly to FIG. 4, a system block diagram of acomputer system 10 is shown having features thereof configured inaccordance to a customer configured computer system order. The computersystem 70 includes a central processing unit (CPU) 72, input/output(I/O) devices, such as a display, a keyboard, a mouse, and associatedcontrollers and collectively designated by a reference numeral 74, atleast one hard disk drive 76, and other storage devices, which mayinclude a floppy disk drive or a CD-ROM drive, and the like, arecollectively designated by a reference numeral 86. Various othersubsystems, such as a network interface card (NIC), are collectivelydesignated by a reference numeral 84. Computer system 70 furtherincludes memory 80, such as random access memory (RAM) and read onlymemory (ROM). The various components are interconnected via one or morebuses, shown collectively as a bus 82. Computer system 70 furtherincludes a SCSI (small computer system interface) controller 78 or othersuitable interface (e.g., IDE, etc.) coupled between the CPU 72 and theat least one hard disk drive 76. For instance, the SCSI controller 78and at least one hard disk drive 76 may form a redundant array ofinexpensive disks (RAID). The computer system described in FIG. 4 istypical of the type of computer hardware that may be ordered by acustomer.

FIG. 5 illustrates a flow diagram view of a computer systembuild-to-order manufacturing process including use of a consolidatedmanufacturing cell according to the present disclosure. According to anembodiment of the invention, a customer order is taken in step 60. Thematerial preparation happens in step 62. The assembly, burn and test,including FCC testing, the wipedown and boxing of the BTO computersystem all happens in step 64. The computer system then gets directshipped in step 66. The customer receipt of the computer system is thelast step 68.

FIG. 6 is a plan view layout of the manufacturing process according tothe present disclosure. The layout is broken up into a MaterialPreparation area 90, a Transformation Process area 92, and a Direct Shiparea 94. The process is also controlled by a central controller 96.

FIG. 7 is a plan view of a portion of the layout of FIG. 6, enlarged toshow greater detail of the Material Preparation area 90 and theTransformation Process area 92. Operators 110 are surrounded by verticalcarousels 100, box erectors 102, A frame 104, conveyor belts 106,overhead conveyors 107, chassis units 108, hold shelving 109 and worktables 111. In addition, consolidated assembly cells 112 are depicted inthe transformation area along with the conveyors 106 and the overheadconveyors 107. Each element will be explained in further detail later inthe text.

In one embodiment, the central controller 96 includes a build-to-orderfactory computer. The build-to-order factory computer may include acontrol unit capable of receiving a product order describing a productto be assembled, the control unit including a list of product componentsfor the product to be assembled. A kitting unit of the MaterialPreparation area 90 is coupled to the control unit and configured toreceived the list of product components, wherein the kitting unitincludes a plurality of kit trays (or totes), a plurality of storedproduct components, and a product component list display device. Theproduct component list display device is configured to display the listof product components for enabling preparation of a kit tray withproduct components having been pulled from the stored product componentsin the Material Preparation area 90. The kitting unit can be coupled tothe consolidated manufacturing cell 112 in the Transformation Processarea 92 via conveyor 107, further assembly of the product using theproduct components from the prepared kit tray at the consolidatedmanufacturing cell 112.

FIG. 8 is a schematic view of an exemplary consolidated manufacturingcell 112 according to one embodiment. The overhead conveyor 107 deliversa kit of parts 113 to the consolidated cell 112 via conveyor elevator oroverhead lift system 114. The kit of parts 113 is put together accordingto a customer order for a custom computer system, the parts having beengathered into a container (or tote) 115 during a kitting operation priorto being delivered to the consolidated cell 112 via overhead conveyor107 and conveyor elevator 114. In other words, the overhead deliveryconveyor 107 is configured to deliver the kit of parts for use in themanufacture of a custom configured computer system. In addition,conveyor elevator 114 is configured to deliver the kit of parts 113 fromthe overhead conveyor 107 to a first work surface of the consolidatedcell 112.

The kit of parts 113, including a computer system chassis 116 in tote115, is delivered to an assembly area proximate the conveyor elevator114. The assembly area is suitable for use in assembling the computersystem from the kit of parts received in tote 115. In particular, thefirst work surface includes a surface of the cell work table and burnstation 117 of consolidated cell 112.

Referring still to FIG. 8, the cell work table and burn station 117include pop-up balls 150 placed on the cell work table to facilitatemovement of the computer system about the surface. The pop-up balls 150can be easily activated, for example, by a foot lever (not shown).

According to one embodiment, the work table and burn station 117 ofmanufacturing cell 112 includes a plurality of burn slots 118. Theplurality of burn slots includes burn slots disposed vertically from oneanother, and burn slots disposed radially about an axis.

For example, in one embodiment, the work table and burn station 117includes twenty-four burn slots 118 and corresponding AC power andcommunication access connections or ports 119. The burn slots 118include eight burn slot columns radially disposed about a vertical axis,further including three vertically disposed burn slots per column. Thevertical axis includes an axis of a dispatch elevator 120, as will befurther discussed below. AC power and communication access ports 119 areaccessible from an exterior of work table and burn station 117 of theconsolidated manufacturing cell 112, as shown in FIG. 8. AC power andcommunication access connections 119 allow for downloading software toan assembled computer system received in a respective burn slot during aburn processing of the assembled computer system.

The work table and burn station 117 further includes a tote lift 120centrally disposed within the work surface. The tote lift 120 can rotateup to 360°. More particularly, central tote lift 120 comprises adispatch elevator. The dispatch elevator dispatches or delivers anassembled computer system to an available burn slot for burn processingof the assembled computer. That is, the dispatch elevator is configuredto move an assembled computer system 113A on a tray into one of thetwenty four burn slots 118. A controller 96A (FIGS. 8 and 9) controls anoperation of the dispatch elevator to deliver the assembled computersystem from the work surface to an available burn slot, further asdiscussed below.

In one embodiment, the dispatch elevator 120 is configured to receive anassembled computer system 113A in a first orientation and to dispatchthe computer system in a second orientation. More particularly, thedispatch elevator 120 includes a cargo surface suitable for receiving anassembled computer system 113A. The cargo surface disposed with respectto the work surface 150 and is configured to move vertically between atleast a first vertical level and a second vertical level. In oneembodiment, the first vertical level corresponds to a vertical level ofthe work surface 150 and the second vertical level corresponds to avertical level of an available burn slot 118. In another embodiment, thecargo surface of the elevator is also disposed for rotational motionbetween a first rotational position and a second rotational position,for dispatching the assembled computer system to one of the plurality ofburn slots radially disposed about the axis. FIG. 8 illustrates the burnslots 118 radially disposed about an axis of dispatch elevator 120.

As mentioned, controller 96A controls the operation of the dispatchelevator to deliver the assembled computer system 113A from the worksurface to an available burn slot. In one embodiment, the controller 96Acontrols the operation of the elevator 120 for delivery of the assembledcomputer system within the available burn slot in a prescribedorientation, the prescribed orientation including power andcommunication ports of the assembled computer system accessible from anexterior of the work table and burn station 117 of the consolidatedmanufacturing cell 112, as shown in FIG. 8. The controller 96A furthercontrols the operation of the elevator for retrieval of a prescribedcomputer system from a corresponding burn slot in response to anindication that burn processing for the prescribed computer system iscompleted. The controller 96A further controls the operation of thedelivery elevator 120 for delivering the prescribed computer system tothe work surface during the retrieval.

In addition, the work table and burn station 117 includes a detector120A configured to detect a presence of an assembled computer system113A placed upon the cargo surface of the elevator 120. Controller 96Afurther controls the operation of the elevator 120 in response to adetection of the assembled computer system by the detector 120A.

The work table and burn station 117 also includes flat screen displays121 for monitoring and controlling the burn slots and other functions ofthe consolidated cell 112. For example, the flat screen displays mayinclude interactive flat panel displays configured to enable interactivecommunications between an operator and the controller 96A ofmanufacturing cell 112. The work table also includes a screwdriver 122for assisting an operator at the work table 117. An overhead box chute123 is configured to deliver shipping boxes 125 to an operator, whilespring stops 124 on the overhead box chute 123 keep the boxes 125 inplace until the operator is ready to use them. Each custom configuredcomputer system is packaged in a prescribed shipping box correspondingto the particular custom configured computer system assembled and testedat the consolidated manufacturing cell 112. In addition, a vacu-hoist(not shown) can be provided to assist in lifting assembled and testedcomputers into the respective shipping boxes when the operator is readyto package them. The conveyor 106 takes finished computer systems to thedirect shipping area, for example, area 94 of FIG. 6.

In another embodiment, the controller 96A includes a means formonitoring an available capacity of the consolidated manufacturing cell112 and for signaling a delivery of a kit of parts 113 to be received atthe work surface in response to a prescribed measure of availablecapacity. For example, the prescribed measure of available capacity cancomprise a function of available burn slots and burn time. In addition,the prescribed measure of available capacity can comprise a function ofthe presence of a kit of parts being assembled on the work surface ofwork table and burn station 117. Still, further the prescribed measureof available capacity can comprise a function of at least one of thefollowing selected from the group consisting of: slots; an availabilityof the burn slots; and a presence of a kit of parts being assembled onthe work surface.

In still another embodiment, the controller 96A provides a means forindicating a completion of burn processing of a prescribed assembledcomputer system, wherein responsive to an indication of completing burnprocessing, the controller 96A signals for a preparation of a shippingbox for the prescribed assembled computer system.

According to yet another embodiment, the central controller 96 of FIG. 6corresponds to a main build-to-order factory computer that interfaceswith controller 96A of the consolidated manufacturing cell 112 of FIG.8. In another embodiment, each custom configured computer system isidentified by a system descriptor record (SDR) and corresponding toidentification of a custom configured computer system manufacturedaccording to a customer order. The main build-to-order factory computer96 and the controller 96A of the consolidated manufacturing cell 112 areconfigured to track the manufacturing of computer systems usingrespective system descriptor records.

Now, for ease of reading the description, the rest of the text break upthe embodiments into specific phases of the improved manufacturingprocess and refer back to FIGS. 7-8 to describe the elements in eachfigure.

Kitting Process

All incoming material is delivered through dock doors proximate akitting area (material preparation area 90). The material is loadeddirectly into material prep equipment. Three types of material prepequipment are utilized in the preferred embodiment, including flow racks(not shown), vertical carousels 100, and automated dispensing systems(not shown) which are known in the art. Flow racks can store any type ofmaterial. However, flow racks are best suited for high volume, oddshaped, sensitive parts. Vertical carousels 100 save floor space and arebest suited for medium volume, odd shaped, sensitive parts. Automateddispensing systems reduce labor requirements and are best suited forhigh volume parts, that are consistent in both shape and weight, and arenot sensitive to automated material handling.

Operators pick prescribed parts from the flow racks/carousel and placethe parts in a tote according to the requirements of a given computerorder. Parts are scanned prior to being placed in the tote, to prevent“Missing and Wrong” manufacturing process errors. The tote is positionedproximate an operators on a manual slide to facilitate part pickingergonomics. Operators work on one tote at a time to reduce the chancesfor “Missing and Wrong” errors.

In the case of the automated dispenser, a tote travels on a smallconveyor, and the automated dispenser machine delivers the appropriatematerials into the tote. At the end of the kitting process, the tote isdelivered to the consolidated manufacturing assembly cells via anoverhead conveyor system 107. A suitable material management softwareprogram is responsible for tracking inventory levels, and notifying thevendor, when supplies are required for replenishment of parts andmaterials.

Assembly Cell Process

The consolidated manufacturing assembly cell 112 is responsible for thefollowing operations which include: chassis/mother board prep, assembly,test/burn, EMR, wipe-down, and boxing and is generally denoted as thetransformation area 92 in FIG. 7 (and shown in detail in FIG. 9).

The assembly cell substantially includes all of the necessary tools andtest equipment to perform a transformation process. Workspace, toolplacement, test equipment, and material delivery for the assembly cellare all optimized to facilitate operator ergonomics and streamline theBTO computer build process.

Substantially all assembly materials needed for a given computer systemassembly, are delivered to a consolidated manufacturing cell 112, via anoverhead conveyor system 107, substantially in synchronization of whenthey are needed in the process. After each computer system unit isassembled, each unit is automatically routed to a local burn processstep area (118 of FIG. 8) of the consolidated manufacturing cell.

The burn process step area utilizes hot-pallet technology such as knownin the art. The hot-pallet technology eliminates the need for repeatedplug and unplug of the computer cabling for the burn process step test.A low cost intelligent material handling system is incorporated into theburn process step area. The material handling system allows for anautomatic loading and unloading of computer systems on a first-infirst-out (FIFO) basis. The “local” burn process step area facilitatesorder purity, and reduces idle work in progress (WIP), and unduly longtravel times. The local burn process step area also facilitates harddrive software download, which is a benefit to the consolidatedmanufacturing cell design.

With the manufacturing process of the present disclosure, EMRtechnicians are a shared resource. EMR technicians are called by anassembly cell as needed to assist with failed computer system units thatrequire advanced skills or special test equipment. By having failedcomputer system units remain primarily at the assembly cell, operatorsget direct feedback on any assembly errors, and can furthermore learnfrom any of the operator's mistakes. Portable EMR carts (not shown) areavailable for transporting special test equipment and replacement partsto an assembly cell.

After burn process step testing, computer systems are automaticallyrouted back into the operator area of the assembly cell. At this time, asuitable message signal or call is placed to the kit boxing portion ofkitting, for a corresponding shipping box 125 to be built and deliveredto the consolidated manufacturing assembly cell 112. While a box 125 isbeing built and delivered, the given computer system is FCC tested,inspected, and wiped down. More particularly, passed systems get an FCClabel, are inspected for cosmetic defects, and then wiped down.Substantially by the time these latter steps are completed for a givencomputer system, the corresponding shipping box arrives 125 via anoverhead conveyor 107. An operator positions the shipping box 125 upon atable top of the assembly cell, and removes documentation contents. Theoperator then uses a Vacu-hoist (not shown) or other suitable liftingtool to load the finished product (i.e., computer system) into theshipping box 125. The documentation contents are then placed back intothe shipping box 125. A ground conveyor system 106 transports thefinished computer system in its shipping box 125 to a taping machine(not shown). The taping machine seals the shipping box 125 andthereafter the around conveyor system 106 transports the sealed shippingbox to Direct Ship (94 shown in FIG. 6).

Boxing/Documentation Process

Documentation and shipping material is initially delivered to thefactory through one or more dock doors located proximate the kittingarea. Upon receipt, the documentation and shipping material is loadeddirectly into appropriate material prep equipment. Four types ofmaterial prep equipment are utilized for documentation and shippingmaterials. The equipment includes: flow racks (not shown), verticalcarousels 100 (referring back to FIG. 7), automated dispensing systems(not shown), and box erectors 102. Flow racks can store any type ofmaterial and are best suited for high volume, odd shaped, sensitiveparts. Vertical carousels 100 save floor space and are best suited formedium volume, odd shaped, sensitive parts. Automated dispensing systemsreduce labor requirements and are best suited for high volume parts,that are consistent in both shape and weight, and are not sensitive toautomated material handling. Box erectors 102 eliminate a manuallyintensive assembly operation and provide space savings.

At the start of the boxing/documentation process for a given customerorder, a shipping box and a Doc-Box (not shown, but would most likely bea box of suitable size for containing documentation for a given customerorder) are constructed in an automated fashion. A Packing Sling is thenplaced inside the shipping box, to protect the computer during shipping.The shipping box, Doc-Box, and packing sling are then routed, forexample, via conveyor, to the documentation area.

At the documentation area, operators pick shipping box and documentationitems and/or parts, according to the requirements of a given customerorder from the flow racks/carousel and place the parts in the Doc-Box.The Doc-Box is positioned proximate the operator, on a manual slide, tofacilitate part picking ergonomics. Operators work on one Doc-Box at atime, to reduce the chances for missing and wrong. In addition, partsare scanned before being placed in a corresponding box. In the case ofthe automated dispenser, the automated dispensing machine delivers therequired materials onto a small tote or bin. When finished, an operatorempties the small tote or bin contents into the Doc-Box, and returns thebin to the automated dispensing machine. At the end of theboxing/documentation line, a shipping label corresponding to a givencustomer order currently being filled is automatically applied to theshipping box. Then the Doc-Box is filled, it is placed inside theshipping box (125 of FIG. 8). The shipping box 125 is then delivered toits respective requesting assembly cell via an overhead conveyor system107. With respect to the boxing/documentation area, a suitable materialmanagement software program tracks inventory levels, and notifies theappropriate vendor when replenishment supplies are required or needed.

As represented by FIG. 9, the present embodiments advantageously providea work cell and process for physically consolidating the transformationprocess of a computer system including motherboard preparation 125,chassis preparation (not shown), assembly 126, EMR 128, burn 130, test132 and boxing 134 during manufacturing of the same into one work area.

The new consolidated manufacturing assembly work cell provides astreamlined process, furniture, fixtures, automation and intelligentcontrols which physically consolidate the steps of the transformationprocess (i.e., chassis prep, mother board prep, assembly EMR, burn, testand boxing). Clearly, this consolidated work cell and process are quitedifferent from prior manufacturing facilities in which theassembly/EMR/burn/test/box steps are carried out in physically separateareas. The consolidation provides numerous current advantages, as wellas provide for future adaptability and scalability.

The consolidated assembly cell of the present disclosure alsostrengthens existing Continuous Flow Manufacturing. For example, theconsolidated manufacturing assembly cell provides on the order ofapproximately four times (4x) productivity impact over the priormanufacturing line process. Throughput on the order of 1050 units perhour are believed possible for a typical line. An improvement on theorder of approximately 250% gain in labor efficiency is estimated, inwhich a previous ratio on the order of 2.3 units/hr/employee is comparedto a new ratio on the order of 5.8 units/hr/employee. Furthermore, thepresent embodiments provide a four times (4x) improvement in factoryfloor space utilization, i.e., in terms of units per hour per squarefoot (units/hr./sq.ft.).

The present embodiment also support a one team/one unit build process.The consolidated assembly cell includes a modular design which greatlysimplifies future build-to-order factory expansion and/or reductionrequirements. The consolidated assembly cell further provides forimproved team communication. The manufacturing process which includesthe consolidated assembly cell also facilitates order purity (i.e.,customers orders are able to be built and tested and shippedcollectively).

The consolidated assembly cell and manufacturing process still furtherprovide for improved ergonomics, for instance, by the elimination ofmanual material handling carts. The need for a separate burn area distalfrom the assembly area is also eliminated. Accordingly, an improvedflexibility in the build-to-order manufacturing of custom configuredcomputer systems is accomplished. The use of overhead material deliverydramatically improves flow and clears previously obstructed or occupiedfloor space. In addition, the present embodiments enable fast responseto manufacturing problems/quality control issues.

What is claimed is:
 1. A consolidated manufacturing cell method for themanufacture of custom configured computer systems comprising: providinga work surface including at least one section suitable for use during anassembly of a computer system from a kit of parts; providing an elevatorincluding a cargo surface suitable for receiving an assembled computersystem and being disposed with respect to the work surface for verticalmovement between at least a first vertical level and a second verticallevel; providing at least one burn slot vertically disposed with respectto the work surface, the at least one burn slot further for receiving anassembled computer system during a prescribed burn processing thereof;and controlling an operation of the elevator to deliver an assembledcomputer system from the work surface to an available burn slot of theat least one burn slot.
 2. The method of claim 1, further including:providing a detector for detecting a presence of an assembled computersystem upon the cargo surface of the elevator, wherein controlling theoperation of the elevator includes controlling the operation of theelevator in response to a detection of the assembled computer system bythe detector.
 3. The method of claim 1, wherein controlling theoperation of the elevator includes controlling the operation of theelevator for delivery of the assembled computer system within theavailable burn slot in a prescribed orientation, the prescribedorientation including power and communication ports of the assembledcomputer system being accessible from an exterior of the consolidatedmanufacturing cell.
 4. The method of claim 1, wherein controlling theoperation of the elevator includes controlling the operation of theelevator for retrieval of a prescribed computer system from acorresponding burn slot in response to an indication that burnprocessing for the prescribed computer system is completed.
 5. Themethod of claim 1, wherein controlling the operation of the elevatorincludes controlling the operation of the elevator for delivering theprescribed computer system to the work surface during the retrieval. 6.The method of claim 1, further including: displaying information to atleast one operator, the information relating to the manufacture of acustom configured computer system.
 7. The method of claim 6, whereindisplaying information includes using an interactive flat panel displayfor enabling interactive communications between an operator and amanufacturing cell controller.
 8. The method of claim 1, furtherincluding: monitoring an available capacity of the consolidatedmanufacturing cell and signaling a preparation and delivery of a kit ofparts to be received at the work surface in response to a prescribedmeasure of available capacity.
 9. The method of claim 1, furtherincluding: providing an overhead lift system for delivering a kit ofparts from an overhead conveyor to the surface area.
 10. The method ofclaim 1, further including: indicating a completion of burn processingof a prescribed assembled computer system; and responsive to theindication, signaling a preparation of a shipping box for the prescribedassembled computer system.
 11. The method of claim 1, further including:providing an overhead shipping box chute for receiving a prescribedshipping box therein, the overhead chute being positioned in proximityto the work surface such that the prescribed shipping box is within easyreach of an operator for placement of the prescribed shipping box ontothe work surface.
 12. The method of claim 11, further including: liftingan assembled and tested computer system from the work surface area intothe prescribed shipping box.
 13. The method of claim 12, furtherincluding: providing a conveyor system for routing a boxed computersystem from the consolidated manufacturing cell to at least one of thefollowing selected from the group consisting of a direct ship area and ashipping distribution center.